A beverage production facility was experiencing severe fouling accumulation on a steam compressor impeller and inlet nozzle, resulting in reduced performance and frequent maintenance requirements. Traditional cleaning methods required removal of the inlet nozzle followed by labour-intensive manual cleaning of the impeller, often involving multiple personnel working across two shifts.

To reduce maintenance demands and improve operational efficiency, Blackstone was engaged to design and supply a custom water wash system capable of cleaning the compressor while in operation.

The project included data acquisition, engineering, fabrication, assembly, installation modifications, and commissioning support. The resulting solution provided a practical and effective method for reducing fouling buildup while extending operating intervals between planned maintenance events.

Design Concept & Wash System Design

• Conduct data acquisition activities on the inlet duct, nozzle, diaphragm, impeller, and volute
• Design a custom water wash system and associated compressor modifications
• Fabricate and assemble the wash system according to engineered specifications
• Modify the inlet duct to accommodate the injection assembly
• Provide commissioning and startup support

Fig 1. Inlet duct installed with the new provisions to accept the wash system

Fig 2. Water Injection Assembly

Several technical challenges were addressed during the project:

• Severe fouling conditions required a dynamic cleaning approach capable of removing deposits while the compressor remained in operation
• Project stakeholders were located across multiple facilities, requiring close coordination throughout engineering and manufacturing activities
• No opportunity existed for physical test fitting of the injection assembly prior to shipment
• Precise fitment was achieved through detailed design reviews and collaboration between Blackstone and project partners
• The final solution needed to be reliable, maintainable, and suitable for operation in a remote facility environment

The custom water wash system delivered several operational improvements:

• Reduced downtime associated with manual cleaning activities
• Significantly decreased labour requirements for compressor cleaning
• Improved safety by reducing personnel exposure to manual cleaning and maintenance intervention activities
• Improved fouling removal efficiency through online water injection during operation
• Extended operating intervals between planned maintenance events
• Simplified maintenance through a removable injection assembly design
• Enabled visual inspection of impeller cleanliness through an integrated inspection port
• Utilized readily available consumables, simplifying procurement and ongoing maintenance support
• Integrated seamlessly with the facility’s existing infrastructure

Following commissioning, the customer confirmed the system successfully reduced fouling accumulation and provided sufficient cleaning performance to safely extend operation until the next planned outage.

Through a combination of engineering expertise, custom design, and close collaboration with project stakeholders, Blackstone delivered a practical water wash solution that improved compressor maintainability, operational performance, and overall reliability.

The project successfully reduced downtime, lowered maintenance labour requirements, improved personnel safety by minimizing manual cleaning activities, and extended operating intervals between planned maintenance events. By reducing fouling accumulation and simplifying ongoing maintenance, the solution helped the facility maximize the performance and lifecycle value of a critical steam compression asset.

The project also represented the first product successfully designed, manufactured, and delivered through the Blackstone-CST collaboration.